106673-4050 ZEXEL F 019 Z20 120 BOSCH INJECTION-PUMP ASSEMBLY f019z20120 1066734050

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 120 f019z20120

ZEXEL 106673-4050 1066734050

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Cross reference number

BOSCH F 019 Z20 120 f019z20120

ZEXEL 106673-4050 1066734050

Zexel num

Bosch num

Firm num

Name

106673-4050

F 019 Z20 120

DPICO

INJECTION-PUMP ASSEMBLY
AM928 Q

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-4420

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.4 4.35 4.45

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.5

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 141 137.5 144.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position R3(5.5)

Pump speed r/min 325 325 325

Each cylinder's injection qty mm3/st. 11 9.4 12.6

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 141 140 142

Basic *

Fixing the lever *

Boost pressure kPa 77.3 77.3

Boost pressure mmHg 580 580

Injection quantity adjustment_04

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 70 150

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-2

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1(11 .5))

Boost pressure kPa 64 60.7 67.3

Boost pressure mmHg 480 455 505

Timer adjustment

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 3.5 2.8 4

Load 4/4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator stroke: BCL (3)Damper spring setting: DL (4)Rack difference between N = N1 and N = N2
----------
BCL=2+-0.1mm DL=(R3-0.2)-0.2mm N1=1000r/min N2=700r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=(12.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=46mm
----------
a=18deg+-5deg b=(31deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = actual measurement (2)Stopper bolt setting (3)(Actual measurement)
----------

----------
a=38deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=6.6+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(6deg)

Information:

Introduction
This Special Instruction provides detailed instructions on the installation of the sleeve into the compensator group of the 3408E and 3412E Unit Injector Hydraulic Pump. If leaks are experienced at the joint of the compensator and the adapter block, the 174-8943 Sleeve may be installed to improve sealing. The new press fit sleeve contains the O-ring more securely than the original slip fit sleeve.Note: Engines built prior to the serial number break that contain the new sleeve have a "S" stamped at the end of the part number on the serial number plate of the pump. The reworked part numbers appear as "144-0835-06S". Individual Components
Table 1
Quantity Part Number Part Description
1 174-8943 Sleeve
1 135-2652 O-Ring
1 033-6039 O-Ring
6 9X-7680 O-Ring Necessary Tools
One of the following tools may be used to insert the new sleeve into the compensator group.
A 31.750 mm (1.250 inch) diameter flat plate.
The 1P-0467 Drive Plate from 1P-0510 Driver Group .
An acceptable bearing insertion tool.Removal Of The O-Ring Seals
Illustration 1 g00638376
Remove the four bolts (1) from the compensator (2). Remove the compensator and the adapter. Do not adjust the compensator. Refer to Special Instruction, REHS0192-03, step 3 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 2 g00638368
Remove the four O-ring seals (3) from the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 4 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 3 g00638372
Remove the four O-ring seals (4) from the two housings. Refer to Special Instruction, REHS0192-03, step 5 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Remove the slip fit sleeve from the compensator housing.Installation Of The Sleeve
Illustration 4 g00637918
(1) Compensator assembly. (2) 174-8943 Sleeve .
Invert the compensator assembly (1). Hold the compensator assembly securely within a vise or a press table.
Start the sleeve (2) by hand into the compensator assembly (1) .Note: It is important that the groove on the outside diameter of the sleeve is oriented toward the O-ring in the joint. If this is not done, there will not be sufficient room to properly seal the O-ring.
Press the sleeve (2) flush with the surface of the compensator assembly (1) using the 1P-0467 Drive Plate or by using an acceptable bearing insertion tool.Installation Of The O-Ring Seals
Illustration 5 g00638368
Install the four O-ring seals (3) on the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 16 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 6 g00638372
Install the four O-rings (4) on the two housings. Refer to Special Instruction, REHS0192-03, step 17 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 7 g00638376
Install the compensator assembly (2) and the adapter as a unit vertically so that the O-rings seals are not damaged. Tighten the four bolts (1) to the following torque.Torque for bolts ... 8 1 N